2012–2013 Polaris Sportsman 400 H.O. / 500 ATV Service Manual (P/N 9923792)

Polaris service manual P/N 9923792, copyright 2012 Polaris Sales Inc., covers the 2012–2013 Sportsman 400 H.O. and 500 models listed above, including South Edition, Touring, Forest and Forest Tractor EFI variants. It documents maintenance, mechanical repair and electrical diagnosis, with separate carbureted and 500 EFI fuel-system sections.

• Engine repair: Engine removal, cylinder-head disassembly, valve inspection, crankcase separation, crankshaft checks and camshaft timing, supported by torque tables and wear limits.

• Fuel systems: Mikuni BST carburetor overhaul and jetting charts, EFI fuel-pressure testing, sensor diagnosis, throttle position sensor initialization and Digital Wrench procedures.

• PVT clutching: Drive and driven clutch disassembly, EBS and non-EBS component inspection, bushing service, belt inspection and clutch alignment.

• Final drive and transmission: Centralized Hilliard gearcase repair, ADC hydraulic bleeding, CV joint and boot replacement, transmission teardown and gear-backlash adjustment.

• Steering, suspension and brakes: MacPherson strut service, ball-joint replacement, steering-post repair, brake bleeding, caliper overhaul and model-specific hydraulic layouts.

• Electrical troubleshooting: Ignition and charging tests, starter-motor repair, starter-lockout diagrams, EFI circuit diagrams and separate vehicle wiring schematics.

This manual is suited to technicians familiar with ATV service procedures and equipped for precision measurement, electrical testing and repairs requiring Polaris special tools.

Engine Inspection, Lubrication and Cooling

The opening sections cover VIN decoding, vehicle identification and factory paint codes, followed by periodic maintenance charts and lubricant listings. Engine repair extends to valve-seat reconditioning, piston-to-cylinder clearance, crankshaft runout and end-play adjustment. Oil-flow diagrams and engine exploded views support component identification.

The valve-clearance section explains the shared exhaust rocker and its dual-feeler-gauge measurement requirement.

Water-pump service: The manual describes mechanical-seal replacement with the engine installed using puller P/N 2872105. Its warning explains how improper puller use can bend the pump shaft, making engine removal and crankcase separation necessary.

Follow the manual’s warnings for pressurized cooling and fuel systems, engine lifting and brake service before beginning work.

Carburetor Service and EFI Diagnosis

The carbureted section covers Mikuni BST operation, disassembly, float inspection and needle-and-seat leakage testing. BST 40 exploded views and altitude-related jetting charts accompany the procedures. International emissions-system and fuel-tank vent-routing illustrations distinguish relevant configurations.

Forest Tractor EFI: Coverage includes fuel-pump testing and replacement, sensor checks, blink-code diagnosis and throttle position sensor initialization. The TPS section warns that disturbing the factory throttle-body stop requires replacement of the complete throttle-body assembly.

Digital Wrench coverage includes trouble-code access, live engine data, guided diagnostics and ECU reflashing. These functions require the separate diagnostic system; the documented reflash process also requires dealer authorization. The manual provides limited manual EFI tests, while directing certain checks to dealer diagnostic software.

PVT Clutches, ADC and Transmission Repair

Separate EBS and non-EBS clutch sections cover internal inspection, one-way clutch checks and bushing replacement. Drive-clutch comparison views identify the differing assemblies, while clutching charts document altitude-specific setups.

Polaris specifies trained, certified Master Service Dealer technicians and factory-authorized special tools for PVT maintenance and repair.

The final-drive chapter distinguishes Centralized Hilliard gearcases with and without Active Descent Control. ADC coverage includes hydraulic-circuit bleeding and piston replacement using tool PA-48542. Transmission procedures extend through internal disassembly, shift-component timing, snorkel/output-gear backlash and reassembly.

Brake Variants, Suspension and Starting Circuits

Brake exploded views distinguish Sportsman, Touring and Forest Tractor arrangements. The Forest 500 section explains its integrated hand- and foot-brake circuits, including the proportioning valve and distribution block. Suspension coverage includes front strut cartridges, rear suspension assemblies and the Forest Tractor seat mechanism.

No-start diagnosis: Separate EFI and carbureted starter-lockout diagrams help distinguish ECU-controlled starting circuits from the conventional H.O. arrangement before testing a fault. Charging-system test diagrams, circuit-protection specifications and EFI sensor references support electrical troubleshooting.

A Preview of Engine and Cooling Specifications

For the carbureted Sportsman 500 H.O., the specification sheet lists a 10.2:1 compression ratio. The intake-valve adjustment section specifies 0.006 in (0.15 mm), with the engine cold and the piston at top dead center on the compression stroke.

The cooling-system reference lists radiator-cap relief pressure at 13 PSI (89.6 kPa), alongside the cap-testing procedure.

Searchable Chapters, Bookmarks and Wiring Sheets

Text search and diagram detail: Workshop text supports PDF searching, and embedded bookmarks navigate the chapters, procedures and wiring sheets. Some illustration labels and the small labels within the final wiring diagrams are not searchable. Fine, light-gray wiring labels require magnification.

The download contains one printable, English-language 438-page PDF: 430 chapter pages, including seven notes pages and two otherwise blank pages, plus eight wiring-diagram pages. All are included in the stated total.